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SAN FELIPE: Step by Step
1
Your parts
a
b
False keelFrame No. 2Bow deckPlanks
SandpaperAnchor x 2Anchor stock x 2
Smooth the edges of all the pieces of wood with sandpaper to
remove any splinters. Do this gently to avoid damaging them. Its
worth penciling the frame number on Frame 2 to help identify it in
future.
Test-fit Frame 2 to the false keel before gluing it. To do this,
place the frame in the second slot of the false keel, and push it
down until it stops. Make sure that it goes all the way to the
bottom of the false keel.
Tools and equipmentWood glueSet squareKnifePencil
ClampsTapeSuperglue
Pack 1
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SAN FELIPE: Step by Step
2
cAfter ensuring that the pieces fit, remove Frame 2 and apply
glue to both sides of the keel, below the second slot.
Re-fit Frame 2 in its position on the false keel. Using a set
square, make sure the two pieces are at right angles. Keep them in
this position while the glue dries.
Cut the planks to a length of 70 mm. You will get two lengths
from each strip, with some likely left over. Then take 10 pieces,
hold them with their edges aligned using clamps, and blacken the
edges using a pencil or a black marker.
d
e
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SAN FELIPE: Step by Step
3
f
g
h
Place some planks on two strips of tape with the sticky side up
and spread glue on them. Take them off the tape, one at a time. To
plank the bow deck, start by aligning the first row of planks to
the deck as shown and then start a second row of planks, placing
them halfway along the first plank, leaving one end
overhanging.
Continue fitting the planks until you have completed the entire
width of the deck, alternating two strips of planking, then three,
as shown.
Once dry, turn over the deck and cut away any planks that extend
past the edge, including over the large cutout and the three large
notches in the side, as demonstrated in the photo.
Do not cut away
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SAN FELIPE: Step by Step
4
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To simulate the nails, take a pencil and mark two points on
either side of where the planks join, as shown.
Apply a drop of superglue to the top end of the anchors, then
insert them into the hole of the stock so that they sit at right
angles. Support them so that the parts arent pushed out of
alignment while you wait for the glue to dry.
The photo shows how the pieces should look at this stage of
assembly. Keep any leftover material, as it will be used later.
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SAN FELIPE: Step by Step
5
a
b
Frame 1Frame 3Bow deckPlanks
Smooth all the pieces of wood with sandpaper to remove any
splinters. Do it gently to avoid damaging them. Test-fit Frames 1
and 3. When satisfied with the fit, apply glue to both sides of the
keel below the slots. As before, it is a good idea to pencil
numbers on them for later identification.
Place Frame 1 on the false keel, pushing it downward until it
stops.
Your parts
Tools and equipmentSandpaper Wood glueSet squarePencil
Knife ClampsTape
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SAN FELIPE: Step by Step
6
c
d
e
Using a triangle or similar straight edge, make sure the two
pieces are at right angles. Hold them in place until the glue is
dry.
Now, apply the glue to either side of the third slot on the
false keel.
Fix Frame 3 in its position on the false keel. Make sure it
dries at a right angle to the false keel.
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SAN FELIPE: Step by Step
7
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Before you begin to plank the other half of the deck, prepare
the planks as you did on pages 2 and 3. Place the two halves of the
deck together in order to continue the pattern of the planks.
Continue fitting the planks until you have completed the entire
width of the deck, as shown in the photo.
Once dry, turn over the deck and cut away any planks that extend
past the edge and the three large notches in the side, as
demonstrated in the photo.
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SAN FELIPE: Step by Step
8
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To simulate the nails, take a pencil and mark points on either
side of where the planks join, as shown.
Temporarily place the two halves of the deck together. Check
that the planks are aligned.
The photo shows how the pieces should look at this stage of
assembly. Keep any leftover material, as it will be used later.
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SAN FELIPE: Step by Step
9
a
b
Smooth all the pieces of wood with sandpaper to remove any
splinters. Proceed gently to avoid damaging them. Then apply glue
to the false keel reinforcement, in the area shown in the
picture.
Glue the false keel reinforcement into place. It needs to be
aligned with the upper edge as well as with the slotted end of the
false keel.
Your partsFrame 4False keelFalse keel reinforcement x 2Bowsprit
deckWooden strip 5 x 5 mm, 300 mm long
Tools and equipmentSandpaper Wood glueClampsSet square
PencilKnife
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SAN FELIPE: Step by Step
10
c
d
e
Repeat Steps a and b from page 9, fixing the other false keel
reinforcement to the other side of the false keel. Hold the
reinforcements in place until the glue is completely dry.
Once dry, apply glue to the new piece of false keel, then insert
it between the two reinforcements until it is in contact with the
previous false keel. Do this on a flat surface, so that they remain
aligned along the top edge.
Hold the reinforcements firmly against the new false keel until
the glue is completely dry.
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SAN FELIPE: Step by Step
11
f
g
h
Now test-fit and glue Frame 4 in its position on the false keel,
as shown.
Next, apply glue to the hull assembly in the areas highlighted
by the red dotted lines in the photo. Slot the bowsprit deck into
place.
Take the 5 x 5-mm strip and position it across the gap in Frame
2, as shown. Mark the length of the gap on the beam and cut the
beam at the mark. Repeat this process to make a lower beam that
will fit as shown on the next page.
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SAN FELIPE: Step by Step
12
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Now apply glue on the joints where the beams will be placed on
Frame 2, as shown in the photo on the left.
Then glue the two beams in place, fitting the lower beam first
and then the upper.
The photo shows how the pieces should look at this stage of
assembly. Keep any leftover material, as it will be used later.
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SAN FELIPE: Step by Step
13
a
b
Smooth all the pieces of wood with sandpaper to remove any
splinters. Do this gently to avoid damaging them. Test-fit Frame 5
in its corresponding slot in the false keel. Apply glue once you
are satisfied with the fit, checking that it dries at a right
angle.
Test-fit Frame 6 in its corresponding slot, then glue into
place, ensuring that it dries at a right angle to the false
keel.
Your partsFrame 5Frame 6Lower deckWooden strip 5 x 5 mm, 300 mm
long
Tools and equipmentSandpaperWood glueSet squarePencil
Knife
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SAN FELIPE: Step by Step
14
c
d
e
Test-fit the lower deck on the frames and the false keel by
carefully pushing it into position as shown in the next step. If
you find it gets stuck on any of the frames while placing it into
position, sand the slots slightly, then try again. Apply glue to
the frames and false keel in the area shown by the dotted red
lines.
Fit the lower deck back in place, making sure that it dries
flat.
Using the 5-mm wooden strip, measure and cut the lower deck beam
of Frame 3.
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SAN FELIPE: Step by Step
15
f
g
h
Apply glue to Frame 3 and fit the beam into place.
Following the same procedure, cut the lower deck beams for
Frames 4, 5 and 6. Once cut, apply glue to each of the frames and
fit into place.
Cut a 70-mm-long strip of wood and glue it in the center of the
beam of Frame 6. Make sure it is perfectly aligned and does not
protrude either above or below the existing beam.
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SAN FELIPE: Step by Step
16
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Test-fit the port bow deck in place. Then apply glue to the
lower beams of Frames 2-6 and glue the deck in place.
Before the glue sets, repeat the last step for the starboard
side bow deck. Once in place, hold both halves down until the glue
has dried.
The photo shows how the pieces should look at this stage of
assembly. Keep any leftover material, as it will be used later.
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SAN FELIPE: Step by Step
17
a
b
Following the same procedure as on page 14, cut and test-fit the
beams for Frames 3 and 4.
Apply the glue to Frames 3 and 4 and fit the corresponding
beam.
Your partsForecastle deckFalse keel reinforcements x
8PlanksWooden strip 5 x 5 mm, 300 mm long
Tools and equipmentKnifePencilSandpaperWood glue
Clamps
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SAN FELIPE: Step by Step
18
cGo over the surface of the deck of the forecastle with
sandpaper to remove any splinters. Then marka line along the center
to divide the deck into two equal parts. Prepare some planks in the
same way as before. To glue, position the first plank up against
the center line, with its end in line with the red dotted line
indicated. Continue planking the deck, overlapping the planks as
before.
Once the deck is covered, turn it over and cut away the
overlapping planks, including those that cover the central hole, so
that it looks like the one shown in the photo. Then use a pencil to
mark points on either side of the joins to simulate the nails.
Apply glue to the areas indicated in red in the photo on the
left.
d
e
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SAN FELIPE: Step by Step
19
f
g
h
Place the forecastle deck so that the upper ledges of the frames
slot into the notches in the deck. Apply some pressure while the
glue dries to ensure that it sticks to the frames and the
beams.
Apply glue to the highlighted areas of the bow in preparation
for fitting the false keel reinforcements.
Place the first pair of reinforcements in the positions shown in
the photo on the left. Repeat this with the second set on the other
side of the bow.
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SAN FELIPE: Step by Step
20
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Now glue the remaining reinforcements flush with the false keel,
on both sides, between the first and second frames and the second
and third frames.
Use clamps to hold the false keel reinforcements in place while
the glue dries.
The photo shows how the pieces should look at this stage of
assembly. Keep any leftover material, as it will be used later.
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SAN FELIPE: Step by Step
21
b
a
Smooth the frames and reinforcements with sandpaper to remove
any burrs.
Apply glue down beyond slot 7 on both sides of the false
keel.
Your partsFrame 7Frame 8False keel reinforcements x 2
Tools and equipmentSandpaper Wood glueSet squareClamps
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SAN FELIPE: Step by Step
22
c
d
e
Place Frame 7 into its corresponding slot by pushing it down
until it is flush with the false keel.
Ensure that the frame dries at an angle of 90 degrees to the
false keel.
Apply the glue down beyond the last remaining slot, on both
sides of the false keel.
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SAN FELIPE: Step by Step
23
f
g
h
Fit Frame 8 into the slot. Push it down until it is in contact
with the false keel and check that it forms a right angle while it
is drying.
Apply glue to the highlighted area of the false keel.
Glue on a false keel reinforcement as shown. This piece needs to
be aligned with the upper edge of the false keel and must not
obstruct the slot where Frame 9 will be inserted.
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SAN FELIPE: Step by Step
24
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Following the same process as in Steps g and h, glue the other
false keel reinforcement into place.
Clamp the false keel reinforcements in place while the glue
dries.
The photo shows how the pieces should look at this stage of
assembly.
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SAN FELIPE: Step by Step
25
a
b
Smooth the frames and false keel with sandpaper to remove any
splintering.
Apply glue to the false keel as shown in the photo.
Your partsFalse keelFrame 9
Tools and equipmentSandpaper Wood glueClampsSet square
Paint brushWood stainKnife File
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SAN FELIPE: Step by Step
26
c
d
e
Slide the new part of the false keel in between the false keel
reinforcements from page 24.
Hold the false keel in place while the glue dries.
Apply glue to the outside of the false keel reinforcements,
highlighted by the red line.
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SAN FELIPE: Step by Step
27
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h
Place Frame 9 in its position on the false keel.
Make sure that the frame dries at a right angle to the false
keel.
The top of Frame 8 protrudes through the main deck, so it is
best to stain it at this point. Use a brush to stain the area above
the black line as shown, working with the grain of the wood.
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SAN FELIPE: Step by Step
28
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Remove the part of Frame 5s beam that can be seen through the
opening in the deck.
Smooth the ends of the section beam you just removed.
The photo shows how the pieces should look at this stage of the
assembly.
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SAN FELIPE: Step by Step
29
a
b
Use sandpaper to remove any splinters from all the pieces of
wood. Then apply glue to the highlighted area of the false
keel.
Place Frame 10 in place in the false keel, holding it as it
dries, and ensuring that it is at a right angle to the keel.
Your partsLower deckBeam Frame 10Wooden strip 5 x 5 mm, 300 mm
long
Tools and equipmentSandpaper Wood glueSet squarePencil
KnifePaint brushWood stain
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SAN FELIPE: Step by Step
30
c
d
e
Apply glue to the highlighted areas of the frames and false
keel.
Carefully place the lower deck onto the frames and false keel.
Hold in place until the glue dries.
Apply glue to the ledges of Frame 8, as shown in the photo.
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SAN FELIPE: Step by Step
31
f
g
h
Place the beam into place on the ledges of Frame 8, with the
projection facing upward.
Cut a beam for Frame 7, using the same technique as with
previous beams.
Once you have cut the beam, glue it into place.
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SAN FELIPE: Step by Step
32
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Now cut and fit a beam for the lower ledge of Frame 9.
Stain the projection in the middle of Frame 8s beam.
The photo shows how the pieces should look at this stage of
assembly. Keep any leftover material, as it will be used later.
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SAN FELIPE: Step by Step
33
a
b
Smooth the deck and frame with sandpaper to remove any
splinters. Then apply glue to the 11th slot of the false keel.
Slide Frame 11 into its slot in the false keel.
Your partsDeckFrame 11Planks
Tools and equipmentSandpaperWood glueSet squarePencil
RulerKnifeFile
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SAN FELIPE: Step by Step
34
cMake sure that Frame 11 dries at a right angle to the false
keel.
Mark a line down the center of the deck.
Position the deck on the frames to test-fit, and adjust if
necessary.
d
e
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SAN FELIPE: Step by Step
35
f
g
h
Apply glue to the areas indicated by the red dotted lines in the
photo, and glue into place.
Cut the planks to a length of 70 mm and mark the edges as with
the previous planks. Start to fix the planks to the deck by placing
the first one along the line drawn in Step d, and the next in the
gap between the planks of the previous part of the deck.
Continue to plank until you reach the edge of the deck. Using
leftover planks, fill in the shorter gaps until the planks are
flush with the edge of the deck.
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SAN FELIPE: Step by Step
36
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Stop planking when your deck reaches the stage shown in the
photo. Cut away any planks that cover the holes in the deck.
Once the holes are cut out, use a file to smooth the edges.
The photo shows how the assembly should look at this stage. Keep
any leftover material, as it will be used later.
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SAN FELIPE: Step by Step
37
Smooth the deck and frame with sandpaper to remove any
splinters. Then, apply glue to the 12th slot in the false keel.
Slide Frame 12 into its slot on the false keel.
a
b
Your partsFrame 12Stern deck3 wooden strips 5 x 5 mm x 300 mm
long
Tools and equipmentSandpaper Wood gluePencilKnife
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SAN FELIPE: Step by Step
38
Carefully test-fit the deck into position. If it is
tight-fitting on any of the frames, sand slightly then re-fit.
Apply glue to the area indicated by the dotted red lines in the
photo.
Fit the deck back into position.
Measure and cut the lower beams for Frames 10 and 11.
c
d
e
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SAN FELIPE: Step by Step
39
Apply glue to the lower ledges of Frame 10, as shown in the
photo.
Glue the lower beam of Frame 10 into place on the lower
ledges.
Glue the lower beam of Frame 11 into place on the ledges.
f
g
h
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SAN FELIPE: Step by Step
40
Measure and cut a beam for the lowest ledge of Frame 12.
Take the beam you cut in the previous step and glue into
place.
The photo shows how the assembly should look at this stage. Keep
any leftover material, as it will be used later.
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SAN FELIPE: Step by Step
41
Use sandpaper to smooth all the new parts. Apply glue to the
13th slot in the false keel, as highlighted by the dotted red
lines.
Slide Frame 13 into its slot in the false keel.
a
b
Your partsFrame 13Stern deckSquare bases
Tools and equipmentSandpaperWood glue
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SAN FELIPE: Step by Step
42
Apply glue to one surface of one of the square bases. Lightly
place it glue side down on the lower deck, aligning it with Frame 8
and the sides of the hatch.
To get the correct position of the base, look at it from above,
through the hatch. It should be centered so that the sides of the
base line up with the sides of the hatch. When it is correctly
positioned, press it down firmly to glue it in place.
Now, repeat Step c for the other base, this time placing it
under the hatch closest to the bow.
c
d
e
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SAN FELIPE: Step by Step
43
Place the second base in the same way as the previous one.
Position it by lining the sides up with the sides of the hatch.
Test-fit each of the halves of the deck in place. Then apply
glue to the beams, as shown.
Place one half of the deck on the frames until it rests on the
beams.
f
g
h
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SAN FELIPE: Step by Step
44
Then apply glue to the exposed beams and slot the other half of
the deck into the frames.
Finally, push the second half of the deck down so that it is
resting on the beams. Hold the two halves in place while the glue
dries.
The photo shows how the assembly should look at this stage. Keep
any leftover material, as it will be used later.
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SAN FELIPE: Step by Step
45
Smooth all the pieces of wood with sandpaper to remove any
splinters. Then test-fit Frame 14 to see where to apply glue to the
false keel, in the area of the dotted red lines shown in the photo
on the left.
Fit Frame 14 in place, making sure it follows the line of the
end of the false keel.
a
b
Your partsFrame 14Stern deckPlanks
Tools and equipmentSandpaperWood glueKnifeFile
Pencil
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SAN FELIPE: Step by Step
46
Cut some planks to fit the gap on the main deck left unplanked
in Step i on page 36.
Once the new planks have dried in place, cut off any that
overlap the edge of the deck and then smooth with a file.
To simulate the nails, take a pencil and add two dots on each
side of the joints between the planks. Repeat this all over the
surface of the deck.
c
d
e
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SAN FELIPE: Step by Step
47
Take one of the 5 x 5-mm strips previously supplied and mark the
length needed to fit across the ledges on Frame 9.
After cutting the beam, glue it in place. Repeat this operation
for beams 10, 11 and 12.
Cut planks 60 mm long and use them to plank the stern deck,
overlapping the joints in the same way as before.
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60 m
m
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SAN FELIPE: Step by Step
48
Use a knife to remove any planks that overhang the openings in
the deck, and sand the edges smooth. Use a pencil to simulate nails
as before.
Glue the completed stern deck on top of the frames and deck
beams.
The photo shows how the assembly should look at this stage. Keep
any leftover material, as it will be used later.
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